21A-1

GROUP 21A

CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . .

21A-2

SERVICE SPECIFICATIONS. . . . . . .

21A-2

LUBRICANTS . . . . . . . . . . . . . . . . . .

21A-2

ON-VEHICLE SERVICE. . . . . . . . . . .

21A-2

CLUTCH PEDAL CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .

21A-2

CLUTCH BLEEDING . . . . . . . . . . . . . . . . .

21A-3

CLUTCH PEDAL. . . . . . . . . . . . . . . . .

21A-5

REMOVAL AND INSTALLATION . . . . . . . .

21A-5

CLUTCH CONTROL . . . . . . . . . . . . . .

21A-6

REMOVAL AND INSTALLATION . . . . . . . .

21A-6

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

21A-8

DISASSEMBLY AND REASSEMBLY . . . . .

21A-8

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

21A-9

CLUTCH

21A-2

GENERAL INFORMATION

GENERAL INFORMATION
M1211000100171

The clutch is a dry single-disc, diaphragm type;

hydraulic pressure is used for the clutch control. The
clutch shares a brake fluid reservoir with the brake
system.

SERVICE SPECIFICATIONS
M1211000300175

Item

Standard value
208 2

Clutch pedal height mm

L.H.drive vehicles

Clutch pedal height mm

R.H.drive vehicles 171.5 2

Clutch pedal clevis pin play mm

13

Clutch pedal free play mm

4 13

Distance between the clutch pedal and the clutch pedal

stopper when the clutch pedal is released mm

L.H.drive vehicles

105 or more

Distance between the clutch pedal and the toeboard when the R.H.drive vehicles 105 or more
clutch pedal is released mm

LUBRICANTS
M1211000400161

Item

Specified lubricant

Quantity

Clutch fluid

Brake Fluid DOT 3 or DOT 4

As required

Pushrod assembly

Rubber grease

As required

Boot

Rubber grease

As required

Release cylinder push rod

MITSUBISHI genuine grease Part

No.0101011

As required

ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND
ADJUSTMENT

Clutch pedal height

<L.H. drive vehicles> <R.H. drive vehicles>
M1211000900199

1. For R.H.drive vehicles, turn up the carpet, etc.

under the clutch pedal.
A
A
Clutch pedal stopper
AC303503 AB

2. Measure the clutch pedal height.

Standard value (A): 208 2 mm<L.H. drive
vehicles>, 171.5 2 mm<R.H. drive vehicles>

CLUTCH

21A-3

ON-VEHICLE SERVICE
Clutch pedal free play

Clutch pedal clevis pin play

C
AC100355 AB

AC100355 AC

3. Measure the clutch pedal clevis pin play.

Standard value (B): 1 3 mm

<L.H. drive vehicles>

Setting nut

<R.H. drive vehicles>

D
D
Clutch pedal
stopper

Clutch pedal
13 2 Nm
AC100356 AB

CAUTION

Do not push in the master cylinder pushrod at

this time, otherwise the clutch will not operate
properly.
4. If the clutch pedal height and clutch pedal clevis
pin play are not within the standard value, loosen
the setting nut to adjust the clutch pedal height
and clevis pin play to the standard value.

AC303504 AB

5. After completing the adjustments, confirm that the

clutch pedal free play (measured at the face of the
pedal pad) and the distance between the clutch
pedal (the face of the pedal pad) and the clutch
pedal stopper when the clutch is disengaged are
within the standard value ranges.
Standard value (C): 4 13 mm
Standard value (D): 105 mm or more
6. If the clutch pedal free play and the distance
between the clutch pedal and the clutch pedal
stopper or toeboard when the clutch is
disengaged do not agree with the standard
values, it is probably the result of either air in the
hydraulic system or a faulty master cylinder,
release cylinder or clutch. Bleed the air, or
disassemble and inspect the master cylinder,
release cylinder or clutch.

CLUTCH BLEEDING
M1211001400175

Clutch master cylinder bleeding<L.H.

drive vehicles with 4G63 engine>
!

CAUTION

Use the specified brake fluid. Do not mix brake

fluids.
Specified fluid: Brake fluid DOT 3 or DOT 4

CLUTCH

21A-4

ON-VEHICLE SERVICE

1. Remove the strut tower bar. (Refer to GROUP42,

Strut tower barP.42-9.)
2. Disconnect the brake tube clamp and remove the
brake master cylinder with the brake tubes
connected.

Clutch release cylinder bleeding

!

CAUTION

Use the specified brake fluid. Do not mix brake

fluids.
Specified fluid: Brake fluid DOT 3 or DOT 4
1. Remove the under cover.

Hose

Clutch master
cylinder
AC304564AB

3. Connect a hose with a bottle to the bleeder screw.

4. Open the bleed nipple.
5. Depress the clutch pedal slowly. Open the bleeder
screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
6. Check that the brake fluid reservoir level stays
between "MAX" and "MIN" marks throughout the
clutch bleeding process.

AC301000AB

2. Connect a hose with a bottle to the bleeder screw.

3. Open the bleed nipple.
4. Depress the clutch pedal slowly. Open the bleeder
screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
5. Check that the brake fluid reservoir level stays
between "MAX" and "MIN" marks throughout the
clutch bleeding process.

CLUTCH

21A-5

CLUTCH PEDAL

CLUTCH PEDAL
REMOVAL AND INSTALLATION
M1211001600180

Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21A-2).
<L.H. drive vehicles>

1
3

7
4
12 2 Nm

<R.H. drive vehicles>

6
12 2 Nm

4
2

7
1

12 2 Nm

5
6
AC304137AB

1.
2.
3.

Removal steps
Instrument panel under cover
(Refer to GROUP 52A, Instrument
panel P.52A-2).
Snap pin
Clevis pin
Clutch master cylinder mounting
nut

4.
5.
6.
7.

Removal steps (Continued)

Clutch pedal assembly mounting
bolt
Pedal pad
Pedal stopper
Clutch pedal assembly

CLUTCH

21A-6

CLUTCH CONTROL

CLUTCH CONTROL
REMOVAL AND INSTALLATION
M1211001900192

Pre-removal Operation
Clutch Fluid Draining
Strut Tower Bar Removal <Wagon-Sport> (Refer to
GROUP42, Strut Tower BarP.42-9 ).

Post-installation Operation
Strut Tower Bar Removal <Wagon-Sport> (Refer to
GROUP42, Strut Tower BarP.42-9 ).
Clutch Fluid Supplying
Clutch Line Bleeding (Refer to P.21A-3).
Clutch Pedal Adjustment (Refer to P.21A-2).

<L.H. drive vehicles>

Release fork

15 1 Nm

10
Release cylinder
push rod

11

Specified grease:
MITSUBISHI genuine grease
PART No. 0101011

6 <4G13, 4G18 engine>

5

30 4 Nm

10

12 2 Nm

2
12 2 Nm

11

<4G63 engine>

18 3 Nm

AC304307 AB

1.
2.
3.
4.
5.

<<A>>

6.
7.
8.

Clutch master cylinder removal

steps
Clevis pin assembly
Eye bolt
Gasket
Reservoir hose
Clevis pin and pushrod assembly
connecting part
Clutch master cylinder
Sealer
Retainer plate

Clutch release cylinder removal

steps
10. Clutch pipe
11. Clutch release cylinder
Clutch line removal steps
9. Clutch hose
10. Clutch pipe

CLUTCH

21A-7

CLUTCH CONTROL

REMOVAL SERVICE POINT

<<A>> CLUTCH MASTER CYLINDER REMOVAL
1. Disconnect the brake tube clamp and remove the
brake master cylinder with the brake tubes
connected.

2. Remove the brake fluid reservoir with the hoses

connected.
3. Remove the clutch master cylinder.

<R.H. drive vehicles>

1

<4G13, 4G18 engine>

3
12 2 Nm

15 1 Nm

8
6, 8

<4G63 engine>

7
Release fork
18 3 Nm

Release cylinder
push rod

Specified grease:
MITSUBISHI genuine grease
PART No. 0101011
AC304305 AB

1.
2.
3.
4.
5.

Clutch master cylinder removal

steps
Clevis pin assembly
Clutch pipe connection
Reservoir hose
Clutch master cylinder
Sealer

6.
7.
8.
9.

Clutch release cylinder removal

steps
Clutch pipe
Clutch release cylinder
Clutch line removal steps
Clutch pipe
Clutch hose

CLUTCH

21A-8

CLUTCH CONTROL

INSPECTION
M1211002000147

Check the master cylinder or clutch hose for fluid

leakage.
Check the clutch hose or tube for cracks or
clogging.

DISASSEMBLY AND REASSEMBLY

M1211002100177

CLUTCH MASTER CYLINDER

!

CAUTION

Do not disassemble the piston assembly.

<L.H. drive vehicles with

4G13, 4G18 engine>

<R.H. drive vehicles with

4G13, 4G18 engine>

13 2 Nm

7
4N
5

1N
2N
5

10
6

10

<L.H. drive vehicles with

4G63 engine>

<R.H. drive vehicles with

4G63 engine>

7
7

5
5
10

9N

10

8
2

3
4
Piston repair kit

Clutch fluid:
Brake fluid DOT3 OR DOT4

Grease: Rubber grease

AC303554AB

CLUTCH

21A-9

CLUTCH CONTROL

1.
2.
>>A<< 3.
4.
5.
6.
7.
8.
9.
10.

Disassembly steps
Piston stopper ring
Piston assembly
Pushrod assembly
Boot
Spring pin
Nipple
Seal
Damper assembly
Gasket
Master cylinder body

REASSEMBLY SERVICE POINT

>>A<< PUSHROD ASSEMBLY INSTALLATION

103 0.5 mm
AC001144 AG

Set the length of the pushrod assembly to the

dimension shown to make the adjustment of the
clutch pedal easier.

INSPECTION

M1211002200141

Check inside the cylinder body for rust and scars.

Check the piston cup for wear and deformation.
Check the piston for rust and scars.
Check the pipe connection for clogging.

127(6